Pulley for extension cord reel

ABSTRACT

A pulley for use in storing an electrical extension cord includes a pulley body having a generally tubular cord winding body with a radially outwardly extending flange formed at one end of its exterior surface. A generally disk-shaped flange plate is releasably attached to the other end of the winding body by locking tabs formed on the winding body which cooperate with apertures formed in the flange plate. Typically, the pulley body is formed of a nylon material and the flange plate is formed of steel. The winding body includes an internal wall and an aperture is formed in the wall and another aperture is formed in the flange plate for rotatably mounting the pulley on a supporting shaft. A coil spring has one end attached to the shaft and the other end attached to the winding body for automatically rewinding the extension cord.

BACKGROUND OF THE INVENTION

The present invention relates generally to a pulley for use in storingan extension cord in a reel and, in particular, to a two piece pulleyincluding a rewind spring.

Prior art electrical extension cord reel assemblies are typically formedwith an outer metallic case enclosing a cord winding reel and ratchetmechanism. The cord winding wheel is generally formed of several stampedmetal parts including a pair of disk-shaped flanges and a generallytubular winding body. The flanges are attached at opposite ends of thewinding body to form a cord winding area for storing an extension cord.Such a construction is costly in terms of manufacturing and assemblingthe various parts.

SUMMARY OF THE INVENTION

The present invention concerns a pulley or reel for use in storing anelectrical extension cord in an extension cord reel assembly. The pulleyincludes a pulley body having a generally tubular winding body formedwith a radially outwardly extending flange near one end thereof. Agenerally disk-shaped flange plate is releasably attached to the otherend of the winding body by generally axially extending locking tabsformed on the winding body which releasably engage apertures formed inthe flange plate. The winding body can also have locating tabs formedthereon for engaging other apertures in the flange plate which locatingtabs and apertures are positioned so as to define a predetermined radialrelationship between the winding body and the flange plate.

The winding body and flange plate are rotatably mounted on a supportingshaft and a coil spring is connected between the supporting shaft andthe winding body for automatically rewinding the cord. The winding bodyand flange can be formed integrally from a nylon material which tends toinsulate the electrical connections between the extension cord and acord leading from an outer case to be plugged into a power source. Also,a pawl is rotatably mounted on an outside surface of the flange platefor cooperation with a detent mechanism. Retaining slots are provided inthe flange plate and the winding body for a ground strip utilized toground the metal flange plate to a ground wire of the extension cord.

It is an object of the present invention to provide an extension cordreel which is less costly to manufacture and assemble than prior artcord reels.

It is another object of the present invention to provide a pulley for anextension cord reel assembly which can be easily disassembled forrepair.

BRIEF DESCRIPTION OF THE DRAWINGS

The above as well as other objects of the invention may become apparentto one skilled in the art from reading the following detaileddescription of a preferred embodiment of the invention when consideredin the light of the attached drawings in which:

FIG. 1 is an exploded perspective view of a pulley for an extension cordreel according to the present invention;

FIG. 2 is a front elevational view of a flange plate included in thepulley shown in FIG. 1;

FIG. 3 is an enlarged, fragmentary cross-sectional view taken along theline 3--3 in FIG. 2;

FIG. 4 is an enlarged, fragmentary cross-sectional view taken along theline 4--4 in FIG. 2;

FIG. 5 is an front elevational view of a pulley body included in thepulley shown in FIG. 1;

FIG. 6 is an enlarged, fragmentary cross-sectional view taken along theline 6--6 in FIG. 5; and

FIG. 7 is an enlarged, fragmentary cross-sectional view taken along theline 7--7 in FIG. 5.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 is an exploded perspective view of a pulley or reel 11 for use inan extension cord reel assembly. The pulley 11 includes a pulley body 12which cooperates with a flange plate 13 to enclose and retain a returnspring 14. The pulley body 12 has a generally tubular cord winding body15 having a radially outwardly extending flange 16 formed at one endthereof. A radially extending internal wall 17 is located intermediatethe ends of the body 15 and has a centrally located aperture 18 formedtherein. The central aperture 18 accepts one end of a supporting shaft19. The shaft 19 has a centrally located radially extending aperture 20formed therein for receiving a pin or rivet 21.

The spring 14 is of the coil type formed of a continuous length of flatsteel spring stock. At an inner end of the coil, an aperture 22 isformed through which the pin 21 extends before entering the aperture 20in the shaft 19. Thus, the pin 21 attaches the inner end of the returnspring 14 to the shaft for rotation therewith. The spring 14 and shaft19 assembly is inserted into the interior of the cord winding body 15through the open end opposite the flange 16. This open end is thenclosed by the flange plate 13. The outer end of the spring 14 has a pinor rivet 23 attached thereto. The head of the pin 23 is received in aslot 24 formed in the interior of the wall of the body 15 and extendinggenerally parallel to the longitudinal axis of the body 15 and thelongitudinal axis of the shaft 19. The slot 24 retains the outer end ofthe spring 14 stationery with respect to the pulley body 12 as the shaft19 is being rotated, as will be described below.

The flange plate 13 is generally disk-shaped with a central cup-shapedportion 25. The cup-shaped portion 25 is dimensioned to fit inside thewall of the cord winding body 15 such that the outer edge of the end ofthe body 15 abuts the inwardly facing surface of an outer rim portion 26of the flange plate 13. A central aperture 27 is formed in the centralportion 25 to receive an opposite end of the supporting shaft 19. Asshown in FIGS. 1 and 2, the flange plate 13 has a plurality of smalleropenings 28 and larger openings 29 formed in the rim portion 26 adjacentthe transition to the cup-shaped portion 25.

The pulley body 12 has a plurality of shorter locating tabs 30 extendingaxially from the edge of the cord winding body 15 facing the flangeplate 13. The tabs 30 cooperate with the smaller openings 28 in theflange plate 13 to locate the flange plate in a radial position withrespect to the pulley body 12. The pulley body 12 also includes aplurality of longer locking tabs 31 which cooperate with the largeropenings 29 in the flange plate 13 to releasably retain the pulley body12 and the flange plate 13 together. The flange 16, the rim 26 and thebody 15 cooperate to define an extension cord storage area. Typically,the pulley body 12 is formed of a nylon material and the flange plate 13is formed of a metal such as steel.

The pulley assembly 11 includes a ground strip 32 having one end 33adapted to accept a terminal (not shown) attached to a ground wire of acord to be wound on the reel. An opposite end 34 is bent at right anglesto the body of the ground strip 32. The ground strip 32 extends in agenerally axial direction along the inner surface of wall of the cordwinding body 15 with the terminal end 33 extending through an aperturein the wall 17 as will be discussed below and the other end 34 retainedin a pocket as will be discussed in connection with FIGS. 2 and 3. Theground strip 32 is formed of an electrically conducting material and isutilized to connect the ground wire of an extension cord to theelectrically conducting body parts of the pulley 11 such as the flange13.

A pawl 35 is rotatably mounted on a boss 36 formed on the centralportion 25 of the flange plate 13. The boss 36 extends in an axialdirection from the outwardly facing surface of the central portion 25and includes an aperture 37 formed therein. The pawl 35 has a steppedaperture 38 formed therein for receiving the head of a pin or rivet 39.The body of the pin or rivet 39 extends through the aperture 37 and theboss 36 and is flattened to pivotally retain the pawl 35 on the boss 36.The pawl 35 also has a smaller aperture 40 formed therein for receivinga pin or rivet 41 which then extends through one looped end of a tensionspring 42. The opposite end of the spring 42 is retained by a tab 43formed near the outer periphery of the central portion 25.

Referring to FIGS. 2 and 3, the other end 34 of the ground strip 32 isinserted into a retaining slot 44 which exposes a portion of the end 34on the outer surface of the central portion 25 of the flange plate 13.The retaining slot 44 is formed at the periphery of the central portion25. A generally square section 45 of the portion 25 is outlined bydeforming the wall axially outwardly toward the rim portion 26 to forman enclosing wall 46. A pair of slots 47 spaced apart along a radialline from the center of the aperture 27 through the retaining slot 44permits the insertion of the end 34 of the ground strip 32.

There is shown in FIG. 4, in greater detail, the boss 36 and the tab 43.The boss 36 is formed by extending a generally circular portion of thecentral portion 25 in an axial direction toward the outwardly facingsurface of the flange plate 13. The center of the boss 36 is formed witha planar surface generally parallel to the surface of the centralportion 25. Also shown is the aperture 37 for receiving the body of thepin or rivet 39. The aperture is of a sufficient diameter to accept asmaller diameter end of the pin or rivet 39 which has a stepped shankwith a portion of the shank closer to the head having a larger diameterthan the other end of the shank. Thus, the step provides a stop for thepin 39 as it is inserted in the aperture 37 thereby rotatably retainingthe pawl 35 on the larger diameter portion of the shank between the boss36 and the head of the pin 39. The tab 43 is formed by cutting agenerally U-shaped slot in the central portion 25 and bending thecentral portion thereof toward the inner surface of flange plate 13.

There is shown in FIG. 5 the outwardly facing surface of the pulley body12. The cord winding body 15 has the radially outwardly extending flange16 formed adjacent an outer edge thereof. The wall 17 is spaced inwardlyfrom the flange 16 (see FIG. 7). A pair of walls 48 and 49 extend inalmost a complete circle about the central aperture 18. The walls 48 and49 also extend radially to join the cord winding body 15 and form achannel 50 for directing an extension cord (not shown) to the interiorspace defined by the walls. The extension cord typically is a three wireassembly. The wires (not shown) are positioned in a predeterminedfashion by a plurality of upstanding walls 51 extending from the surfaceof the wall 17. The ends of the extension cord are adapted to beconnected in a known fashion to a power cord attached to an outer case(not shown) for enclosing the pulley 11 and including a plug forinsertion into a power source receptacle.

There is shown in FIG. 6 a portion of the cord winding body 15 and theflange 16 showing one of the locking tabs 31. Each of the locking tabs31 is formed with an enlarged head portion 52 having a ramp surface 53formed thereon. As the flange plate 13 is moved into locking engagementwith the pulley body 12, each of the enlarged heads 52 will have itsramp surface 53 come into contact with the inwardly facing surface ofthe rim portion 26. The locking tabs 31 will be forced radiallyoutwardly until the enlarged heads 52 snap through the correspondingones of the larger openings 29 and snap into locking engagement.

There is shown in FIG. 7 a cross-sectional view of a portion of thepulley body 12 including an aperture 54 formed in the wall 17 foraccepting the terminal end 33 of the ground strip 32. At least a portionof the inner surface of the cord winding body 15 on the inwardly facingside of the wall 17 cooperates with the wall 55 to form a passage 56 forthe central body of the ground strip 32. On the opposite, or outwardlyfacing side of the wall 17, the cord winding body 15 is displacedradially outwardly as at 57 to provide an area for receiving a femaleelectrical terminal on the male end 33 of the ground strip 32.

If one or both of the supporting shaft 19 are fixed with respect to, forexample, an outer case, the pulley body 12 and flange plate 13 can berotated together to wind and unwind the spring 14. Thus, rotation in acounterclockwise direction as viewed from the flange plate 13 end of theshaft 19 will tend to wind up or tighten the spring 14. Such rotation isusually accomplished by pulling the extension cord to unwind it from thebody 15. When the force unwinding the cord is released, the spring 14will tend to unwind thereby rotating the pulley in a clockwise directionto wind up the cord on the body 15. The pawl 35 will cooperate with aconventional detent mechanism (not shown) to prevent winding by thespring 14 when the extension cord is extended until the detent isdisengaged.

In accordance with the provisions of the patent statutes, the presentinvention has been described in what is considered to represent itspreferred embodiment. However, it should be noted that the invention canbe practiced otherwise than as specifically illustrated and describedwithout departing from its spirit or scope.

What is claimed is:
 1. A pulley for use in storing an electricalextension cord comprising:a pulley body having a generally tubular cordwinding body with a radially outwardly extending flange formed on itsexterior surface; a generally disk-shaped flange plate having agenerally axially extending boss formed thereon and a tab spaced fromsaid boss and including a pawl and a spring, said pawl being rotatablymounted on said boss and said spring having one end attached to saidpawl and an opposite end retained by said tab; and means for releasablyattaching said flange plate to one end of said winding body, said flangeplate, said outwardly extending flange and said winding body defining astorage area for an electrical extension cord.
 2. The pulley accordingto claim 1 wherein said pulley body is formed of a nylon material. 3.The pulley according to claim 2 wherein said flange plate is formed ofsteel.
 4. The pulley according to claim 1 wherein said winding body isopen at opposite ends and has a generally radially extending internalwall formed intermediate said ends.
 5. The pulley according to claim 4wherein said internal wall and said flange plate each have a centralaperture formed therein and including a supporting shaft having oppositeends retained in said apertures.
 6. The pulley according to claim 1wherein said pulley body and said flange plate are rotatably mounted ona supporting shaft and including a spring means attached to said shaftand to said pulley body for rotating said pulley body and said flangeplate about said supporting shaft.
 7. The pulley according to claim 1wherein said means for releasably attaching includes at least oneaperture formed in said flange plate and at least one locking tab formedon said pulley body, said locking tab releasably engaging said aperturewhen said flange plate abuts said pulley body.
 8. The pulley accordingto claim 7 wherein said locking tab includes an enlarged head portionhaving a ramp surface formed thereon.
 9. An extension cord reel pulleycomprising:a generally tubular winding body; a radially outwardlyextending flange attached to said winding body; a generally disk-shapedflange plate; means for releasably attaching said flange plate to saidwinding body in spaced apart relation to said flange; a supportingshaft, said winding body and said flange plate being rotatably mountedon said supporting shaft wherein said winding body and said flange areformed as an integral pulley body having a generally radially inwardlyextending wall formed in said winding body and an aperture formed insaid wall for retaining an end of said supporting shaft; and said wallhaving another aperture formed therein and said flange plate having aretaining slot formed therein and including a ground strip having aterminal end extending through said another aperture and another endretained in said retaining slot.
 10. The pulley according to claim 9wherein said pulley body is formed of a nylon material.
 11. The pulleyaccording to claim 10 wherein said pulley body has a plurality ofgenerally axially extending locking tabs formed thereon and said flangeplate has a plurality of apertures formed therein, each of said lockingtabs releasably engaging a corresponding one of said plurality ofapertures.
 12. The pulley according to claim 11 wherein said pulley bodyhas a plurality of generally axially extending locating tabs formedthereon, each of said locating tabs engaging a corresponding one of saidplurality of apertures, said locating tabs and said correspondingapertures being positioned to radially orient said flange plate withrespect to said pulley body.
 13. The pulley according to claim 10wherein said flange plate is formed of steel and includes an aperturefor retaining an opposite end of said supporting shaft.
 14. A reel foruse in winding a flexible cord comprising:a generally tubular windingbody having a radially outwardly extending flange formed on an outersurface thereof adjacent one end of said winding body; a generallydisk-shaped flange plate having a plurality of apertures formed therein;said winding body and said flange plate being rotatably mounted on asupporting shaft and including a coil spring having one end attached tosaid shaft and an opposite end attached to said winding body; and aplurality of locking tabs formed on said winding body at an oppositesaid flange, each of said locking tabs releasably engaging acorresponding one of said apertures whereby said flange plate isreleasably attached to said winding body in spaced apart relation tosaid flange to define a cord winding area on said outer surface of saidwinding body.
 15. The reel according to claim 14 wherein said windingbody includes a plurality of locating tabs formed thereon and extendingin a generally axial direction to engage corresponding ones of saidplurality of apertures, said locating tabs and said corresponding onesof said plurality of apertures being positioned to define apredetermined radial relationship between said winding body and saidflange plate.
 16. The reel according to claim 14 wherein said windingbody and said flange are formed of a nylon material and said flangeplate is formed of steel.